Stone mold



Ot. 22, 1957 H. c. BARNACK 2,810,180

STONE MOLD Filed June 25. 1954 [NVEN'I OR.

Iazy'admwk ATTDRN EYS STONE MOLD Henry C. Barnack, West Springfield, Mass.

Application June 25, 1954, Serial No. 439,275

1 Claim. (Cl. 25 1) This invention relates to a molding arrangement for a building construction, and more particularly to a mold for applying stone-like materials to a wall.

The object of the invention is to provide an apparatus for producing a stone-like finish on a wall surface.

Another object of the invention is to provide a mold that does not utilize wax paper so that lines and creases will not be left in the exposed surface as is the case when wax paper is used, the mold utilizing a lubricant which serves to keep the stone clean longer and also serves as a waterproofing agent as well as preventing the mix from sticking to the mold.

A further object of the invention is to provide a mold which is extremely simple and inexpensive to manufacture.

Other objects and advantages will be apparent during the course of the following description.

ln the accompanying drawings, forming a part of this application, and in which like numerals are used to designate like parts throughout the same:

Figure l is a perspective View of the mold.

Figure 2 is a sectional view taken through a wall and showing the mold being used by means of a rolling longitudinal movement to apply the mix to the wall to provide a stone-like nish on the Wall.

Figure 3 is a front elevational view showing a portion of a completed wall having the stone-like finish thereon.

Figure 4 is a sectional view taken on the line 4 4 of Figure 3 and showing only the mold.

Figure 5 is a fragmentary sectional view taken through the mold showing the mortar therein and showing the lubricant in the mold.

Figure 6 is a fragmentary sectional view showing the mold being used for producing a corner finish on a wall.

Figure 7 is a fragmentary sectional view taken through a completed wall and showing the mortar joints between the slabs.

Referring in detail to the drawings, the numeral 10 designates a mold which can be made of any suitable material, and the mold 10 includes a curved or arcuate base 11, Figures l and 2.

Extending from one side of the base 11 and secured thereto is a rectangular continuous flange which includes spaced parallel end sections 12 and spaced parallel end sections 14. The end or side sections 14 are curved in order to conform to the curvature of the base 11.

The mold 10 is further provided with a plurality of vent openings or holes 15 whereby air pockets will not develop in the slabs being produced and whereby the slabs 13 can be readily removed from the mold 10 without the formation of a vacuum. Portions of the base 11 may be enlarged or recessed as at 16, and these irregular surfaces 16 serve to insure that the completed slabs 13 will have indentations and protuberances similar to natural stone such as shown in Figure 3. A handle 17 is secured to the mold 14) in any suitable manner, whereby the slab 13 can be applied to the wall by means of a longitudinal rolling motion.

Patented Oct. 22, 1957 Heretofore it has been the practice to use wax paper within the mold so as to help prevent sticking'of the material 13 to the mold. However, with the present invention no wax paper is used since a suitable lubricant 18 may be smeared or rubbed on the inner surface of the mold 10 as shown in Figure 5. The numeral 19 designates a portion of a building to which the stone-like nish is to be applied, and an inner coat 20 and an outer coat 21 of cementitious material may be applied to a portion of the wall 19. The coat 20 may be the usual brown coat, while the coating 21 may be the scratch coat, and the slabs 13 are applied to the outer coat 21 by means of a rolling motion. When applying the cementitious mixture or slab'13 to the wall, the operation is accomplished as shown in Figure 2 so that one end of the mold is arranged against the wall, and then by means of a rolling -rnotionI the mold 10 is moved from the solid line position of Figure 2 to the broken line position of Figure 2 whereby the slab 13 which is Wet and soft will adhere to the coating 21 so that it will easily be removed from the mold due to the provision of the lubricant 18.

Referring to Figure 6 of the drawings the mold is shown being used for applying a corner slab 13 to the wall 19. Again the mold 10 is used in a rolling fashion so that one end of the mold is arranged against the wall and then the mold is rolled around the corner so that the finished slab 13 has a substantially L-shape.

j From the foregoing it is apparent that there has been provided a method of and apparatus for forming and applying stone-like materials to a wall. The mold can be made of any suitable material such as metal and it is not necessary to use wax paper in the mold so that lines and creases will not be in the finished article since such lines are caused by the wax paper. Instead of using the wax paper the lubricant 18 is used and this also serves to waterproof the surface and to keep the stone clean longer as well as to prevent the mix from sticking to the mold 10. A silicone material may be used as the lubricant. The mold applies the slab or stone with a clean recessed mortar joint 23. When using the mold, a cement stucco or brown coat 20 may be first applied to the Wall 19 by any suitable means, and before this inner coat 20 sets, another coating 21 may be applied, and before the coating 21 sets or becomes hard, the stone or slab 13 or 13 is applied to leave the space 23 between the calender stones and this space is the mortar joint. The mix may be of different colors and the coloring can be achieved by using different colored sand or color of any desired composition. The color will extend throughout the entire stone veneer so that the color will remain permanently in the stone and not only on the surface. A stiff mix can be used so that the natural curves and chips of stone can be brought out better to provide a more realistic appearance whereas when using wax paper and a soupy mix, this cannot be accomplished. The curve in the mold permits much more pressure to be applied on each section of the mold as it is rolled on from one end of the mold to the other than could be exerted on a flat mold where pressure is brought to bear on the entire flat mold at one time. Thus, the mold forms a superior bond between the stone and the cement stucco 21 or whatever material is used as an undercoat. Also, the mold permits the application of the stone around a corner as shown in Figure 6 in one operation. Furthermore, by rolling the stone, guesswork will be eliminated since formerly guesswork was required to slap the mold onto a wall when it contained a soupy mix since such a soupy mix might fall out of the mold if held in a vertical position whereas the firm mix that can be used with the mold of the present invention will not fall out of the mold even in a vertical position. If additional strength is required, the additional coat 20 can be applied to the wall before the brown coat 21 and the ,the stone to come out of the mold clean. joints 23 are nished without being lled in completely first coat 20 may be the scratch coat and it can be applied and scarified and then left to dry hard. Then, the second coat which may be the brown coat 21 can be applied over the scratch coat 20. Air vent openings 15 may ,not always be necessary but depend upon the mix being used. Also, the design produced by the mold ,can be varied as desired. Preferably the lubricant 18 is of a type that dries hard since an oily lm that does not dry will catch dust and the lubricant may be brushed on the inside of the mold with a paint brush. The molds do not have to be cleaned `very often, but in'the event that they do haveA to be cleaned a solvent can be brushed therein and continued use of the molds automatically keeps them clean.

The `mortar joints which show between the stones are clean cut and can be of any color desired by using whatever color is desired or needed in the brown coat 21.` kIn cinder block or` cement block construction, one coat of stucco will Ybe suicient before applying the slabs or stones 13. The mold 10 is curved so that when it is filled wiht colored stucco or cement, one end can be brought in contact with the surface that the stone is being applied to, and'then the mold is rolled to the opposite end and pulled away to leave the stone stuckto the wall. After the stone` has been applied in a random or bricklike fashion, a pointing tool can be used to make the mortar joints 23 so that there will be provided a wall that is waterproof, hard, and realistic in appearance. The rolling action of forcing the stone onto the wall insures that the stone or slab will stick better and also allows The mortar in mortar. A pointing tool may be run through the joints 23 if a rounded ctect is desired at its base.

Furthermore, the same molds can be used over a freshly stuccoed surface to roll in the stone imprint by merely using the lubricant and an empty mold. The empty mold process can also be used `on cement ooring, preferably with a smooth mold for a smoother Walking surface, and in this case the mortar joint would be filled in possibly after the stone has hardened.

I claim:

In a mold, a base having a concavo-convex shape and provided with a plurality of vent openings, said base also having a plurality of indentations and enlargements to cause the finished product to have a natural stone-like appearance, a continuous rectangular flange extending from one side of said base and secured thereto, said ange including spaced parallel end sections, and spaced parallel side sections, said side sections being curved to conform to the configuration of the base, and a handle secured to the opposite ends of said base and extending across the concave face of said base,

References Cited in the tile of this patent UNITED STATES PATENTS 868,284 Mills Oct. 15, 1907 1,194,554 Seiler Aug. 15, 1916 1,933,237 Aberson Oct. 31, 1933 1,960,276 Miller May 29, 1934 2,151,597 Hamilton Mar. 2l, 1939 2,505,342 Schaaf Apr. 25, 1950 2,517,432 Hornbcrger Aug. 1, 1950 2,648,887 Reicherd Aug. 18, 1953 

